In-line sander

ABSTRACT

An in-line sander comprising a sander body which houses a motor coupled to an in-line oscillating mechanism. The in-line oscillating mechanism is adapted and configured to move a sanding pad in a linear oscillating motion.  
     A corner or detail pad has a substantially flat lower surface and a substantially pointed front portion bounded laterally by two substantially-linear corner-sanding edges having an included angle of less than 90 degrees. A forward end of this substantially pointed front portion of the preferred corner or detail pad protrudes ahead of a front end of the sander body throughout the linear oscillating motion of the pad. The front portion of the preferred corner or detail pad has particular application for sanding into corners of a carcass. For example, with the preferred detail or corner pad installed, when the sander is in use where three workpiece surfaces of a carcass meet one another perpendicularly to form a corner, sandpaper supported by the pad under the forward end of the pad will effectively sand into the corner on any included surface of the corner.  
     A preferred embodiment of the present corner or detail pad has at least one substantially linear side edge which is aligned substantially parallel to the linear oscillating motion of the sander. This substantially linear side edge of the pad protrudes laterally at least as far as the maximum width of the sander body. With such a configuration, when the sander is in use where two workpiece surfaces meet one another at an included angle along edges of less than 180 degrees, the surfaces of each workpiece which form the included angle can be sanded up to the adjoining workpiece surface by sandpaper supported by the pad under the substantially linear side edge of the pad.  
     An alternate preferred sanding pad, sometimes referred to in the present application as a shutter pad, has at least one extended substantially linear side edge which is aligned substantially parallel to the linear oscillating motion of the sander and which extends laterally a conspicuous distance beyond the maximum width of the sander body. With such a shutter pad configuration, when the sander is in use on a project such as the louvers on a shutter, where a lower workpiece upper surface is below an upper workpiece by a distance greater than the thickness of the pad but is inaccessible by the sander body, sandpaper supported by the pad below the extended substantially linear side edge can be effectively used on the inaccessible lower workpiece upper surface within the conspicuous distance that the extended substantially linear side edge protrudes laterally beyond the sander body.

CROSS REFERENCE TO RELATED APPLICATIONS

[0001] This application is a continuation of application ser. No.08/851,804 filed on May 7, 1997, which is a file wrapper continuation ofapplication Ser. No. 08/389,277 filed on Feb. 9, 1995.

BACKGROUND AND SUMMARY OF THE INVENTION

[0002] The present invention relates to an in-line sander comprising asander body which houses a motor coupled to an in-line oscillatingmechanism. The in-line oscillating mechanism is adapted and configuredto move a sanding pad in a linear oscillating motion.

[0003] One preferred sanding pad adapted and configured to be coupled tothe in-line oscillating mechanism is sometimes referred to in thepresent application as a corner or detail sanding pad. The preferredcorner or detail pad has a substantially flat lower surface and asubstantially pointed front portion-bounded laterally by twosubstantially-linear corner-sanding edges having an included angle ofless than 90 degrees. A forward end of this substantially pointed frontportion of the preferred corner or detail pad protrudes ahead of a frontend of the sander body throughout the linear oscillating motion of thepad. The front portion of the preferred corner or detail pad hasparticular application for sanding into corners of a carcass. Forexample, with the preferred detail or corner pad installed, when thesander is in use where three workpiece surfaces of a carcass meet oneanother perpendicularly to form a corner, sandpaper supported by the padunder the forward end of the pad will effectively sand into the corneron any included surface of the corner.

[0004] A preferred embodiment of the present corner or detail pad has atleast one substantially linear side edge which is aligned substantiallyparallel to the linear oscillating motion of the sander. Thissubstantially linear side edge of the pad protrudes laterally at leastas far as the maximum width of the sander body. With such aconfiguration, when the sander is in use where two workpiece surfacesmeet one another at an included angle along edges of less than 180degrees, the surfaces of each workpiece which form the included anglecan be sanded up to the adjoining workpiece surface by sandpapersupported by the pad under the substantially linear side edge of thepad.

[0005] An alternate preferred sanding pad, sometimes referred to in thepresent application as a shutter pad, has at least one extendedsubstantially linear side edge which is aligned substantially parallelto the linear oscillating motion of the sander and which extendslaterally a conspicuous distance beyond the maximum width of the sanderbody. With such a shutter pad configuration, when the sander is in useon a project such as the louvers on a shutter, where a lower workpieceupper surface is below an upper workpiece by a distance greater than thethickness of the pad but is inaccessible by the sander body, sandpapersupported by the pad below the extended substantially linear side edgecan be effectively used on the inaccessible lower workpiece uppersurface within the conspicuous distance that the extended substantiallylinear side edge protrudes laterally beyond the sander body.

BRIEF DESCRIPTION OF THE DRAWINGS

[0006]FIG. 1 illustrates a top left perspective view of a preferredembodiment of the present sander configured with a corner or detailsanding pad;

[0007]FIG. 2 illustrates a left side elevational view of the sandershown in FIG. 1;

[0008]FIG. 3 illustrates a right side elevational view of the sandershown in FIG. 1;

[0009]FIG. 4 illustrates a front elevational view of the sander shown inFIG. 1;

[0010]FIG. 5 illustrates a back elevational view of the sander shown inFIG. 1;

[0011]FIG. 6 illustrates a top plan view of the sander shown in FIG. 1;

[0012]FIG. 7 illustrates a bottom plan view of the sander shown in FIG.1, including a bottom plan view of a preferred corner or detail sandingframe (with a preferred corner or detail pad shown in phantom) for usewith the present sander;

[0013]FIG. 8 is a right side elevational cross sectional profile (takenalong cutting line 8-8 of FIG. 6) illustrating the preferred sander, aswell as a preferred profiled pad holding system coupled to the sander;

[0014]FIG. 9 is a right side elevational cross section of a frontportion of the sander (taken along cutting line 9-9 of FIG. 6) showing aportion of the preferred in-line oscillation system as well as apreferred corner or detail sanding pad coupled to the sander;

[0015]FIG. 10 is a front cross sectional view (taken along cutting line10-10 of FIG. 8) including a preferred holding system adapted andconfigured for holding a single, selected profiled sanding pad;

[0016]FIG. 10A is a front cross sectional view (taken along cutting line10A-10A of FIG. 8) including a preferred holding system adapted andconfigured for holding two selected profiled sanding pads;

[0017]FIG. 11 is a partial cutaway drawing including an illustration ofa portion of the preferred in-line oscillation system;

[0018]FIG. 12 is an exploded lower perspective view including a lowerperspective view of two alternate preferred profiled pad frames forrespectively holding a single or two profiled pads, as well as of apreferred corner or detail pad frame;

[0019]FIG. 13 is an exploded upper perspective view of portions of thepreferred in-line oscillation system and an upper perspective view of apreferred corner or detail pad frame;

[0020]FIGS. 14 and 15 are perspective illustrations of partiallyassembled portions of the preferred in-line oscillation system;

[0021]FIG. 16 is an exploded perspective view of components of thepreferred in-line oscillation system;

[0022]FIGS. 17 and 18 illustrate a preferred shutter pad frame and pad;

[0023] FIGS. 19-21 illustrate a preferred pad frame for holding twoprofiled pads;

[0024] FIGS. 22-24 illustrate a preferred pad frame for holding a singleprofiled sanding pad;

[0025]FIGS. 25, 25A, 26, and 27 illustrate the preferred corner ordetail sanding pad frame and pad, including a preferred radius of an atleast slightly-convex, curved sanding edge of the preferred corner ordetail pad frame and pad; and

[0026] FIGS. 28-44 illustrate preferred profiled sanding pads which canbe selectively used with the present sander.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0027] Although the tool or tool system referred to in the presentapplication is referred to as a “sander” which uses “sandpaper”, it willbe recognized that other abrasive papers, abrasive materials, orabrasive systems or the like can be used to replace the “sandpaper”referred to without loss of generality.

[0028] The preferred system is a sanding system which can be configuredinto many highly-versatile configurations. The present sanding system isarranged and configured to alternatively and selectably accept for use acorner or detail pad, a shutter pad, and a wide variety of profiledpads. Such versatility is found in no other sander.

[0029] To accomplish this, the present sanding system preferablyincludes a pad frame system comprising a corner or detail pad frame forsupporting a corner or detail pad for sanding into the corners of acarcass, a shutter pad frame for supporting a shutter pad configured foroperations such as sanding louvers of a shutter blocked by other louverson the shutter, and a profiled pad frame for supporting a profiled padconfigured to power sand pre-configured profiles onto or sand suchprofiles previously configured on a workpiece.

[0030] The preferred sander comprises a sander body 50 which houses amotor 52 (see FIG. 8) coupled to an in-line oscillating mechanism 54.

[0031] A preferred sanding pad frame such as 56 or pad such as 56A maybe coupled to an in-line oscillating mechanism such as 54 for movementin a linear oscillating motion. Such a sanding pad or pad frame, whichis sometimes referred to in the present application as a corner ordetail sanding pad or pad frame, typically has a substantially flatlower surface 58 and a substantially pointed front portion 60 boundedlaterally by two substantially-linear corner-sanding edges 62 having anincluded angle 64 of less than 90 degrees.

[0032] A forward end 66 of the substantially pointed front portion 60 ofpreferred pad frame 56, and the forward end 56B of preferred pad 56A,protrudes ahead of a front end 68 of sander body 50 throughout thelinear oscillating motion of pad frame 56.

[0033] The front portion 60 of preferred pad frame S6 and pad 56A hasparticular application for sanding into corners of a carcass. Forexample, with preferred pad frame 56 with pad 56A installed, when thesander is in use where three workpiece surfaces (not shown) of a carcassmeet one another perpendicularly to form a corner, sandpaper supportedby pad 56A under the forward portion 60 of the pad will effectively sandinto the corner on any included surface of the corner.

[0034] In a preferred embodiment, the substantially-linearcorner-sanding edges 62 each define an at least slightly-convex, curvedsanding edge 70. It has been found that a radius 72 (see FIG. 25) on theorder of 15 inches is appropriate for defining the at leastslightly-convex, curved sanding edges 70 and that such curved edges areuseful when sanding into a corner. In such an application, the at leastslightly-convex, curved sanding edges 70 facilitate a controlledrotation of the forward end 66 of the substantially pointed frontportion 60 of the pad or pad frame into the corner.

[0035]FIG. 25A further illustrates the preferred configuration of padframe 56. At the forward end 66 of preferred pad frame 56, two tangentsdrawn along the at least slightly-convex, curved sanding edges 70 forman angle 64A of approximately 80 degrees. At the trailing edges of thesubstantially pointed front portion of preferred pad frame 56, tangentsdrawn along the at least slightly-convex, curved sanding edges 70 forman angle 64B of approximately 64 degrees. This preferred configurationassists in sanding within corners that are out of square. Sometimesnominally 90 degree corners in woodworking are off by plus or minus fivedegrees or even more. Accordingly, in order to sand into a corner thatis closed by five degrees, the forward included angle of the pad shouldbe less than 85 degrees. For this reason, preferred angle 64A shown inFIG. 25A was selected to be approximately 80 degrees, so that a cornerof up to almost 80 degrees can be sanded. Furthermore, for cornershaving walls bowed in toward the user, an even smaller angle 64B ofapproximately 64 degrees was chosen, in order to allow rotation offorward end of the pad and pad frame into all portions of the corner.

[0036] Although the forward end 56B of preferred pad 56A issubstantially pointed, forward end 66 of the substantially pointed frontportion 60 of pad frame 56 preferably comprises a substantiallyflattened portion 74 joining the two sanding edges at the front end ofthe pad frame. When sanding into a corner, substantially flattenedportion 74 of the substantially pointed front portion 60 of the padframe helps prevent indenting of workpieces by the front end of the padframe.

[0037] In the preferred embodiment, sander body 50 has a maximum width76 (see FIGS. 6 and 7) on the order of 2.5 inches along the length ofthe sander body, and preferred pad frame 56 has at least onesubstantially linear side edge 78 which is aligned substantiallyparallel to the linear oscillating motion. In this preferred embodiment,the at least one substantially linear side edge 78 of pad frame 56protrudes laterally at least as far as the maximum width 76 of sanderbody 50. With such a configuration, when the sander is in use where twoworkpiece surfaces (not shown) meet one another at an included anglealong edges of less than 180 degrees, the surfaces of each workpiecewhich form the included angle can be sanded up to the adjoiningworkpiece surface by sandpaper supported by the pad under the at leastone substantially linear side edge 78 of the pad frame. Preferred padframe 56 has two substantially linear side edges 78 which are alignedsubstantially parallel to the linear oscillating motion. Eachsubstantially linear side edge 78 of preferred pad frame 56 protrudeslaterally at least as far as the maximum width 76 of the correspondingside of sander body 50. With such a configuration, when the sander is inuse where two workpiece surfaces (not shown) meet one another at anincluded angle along edges of less than 180 degrees, the surfaces ofeach workpiece which form the included angle can be sanded up to theadjoining workpiece surface by sandpaper supported by the pad undereither substantially linear side edge of the pad.

[0038] The substantially linear side edges of preferred pad 56A define apad width 80 (see FIGS. 6 and 7) which is slightly larger than themaximum width 76 of the sander body. In the preferred embodiment,preferred pad frame 56 has a width of approximately 2.5 inches. Withsuch a configuration, the sander can be effectively used on a workpiecesurface (not shown) bounded by protruding workpiece surfaces (not shown)only slightly further apart than the maximum width of the sander body.

[0039] Preferred pad frame 56 further comprises a substantially pointedrear portion 82 bounded laterally by two substantially-linearcorner-sanding edges having an included angle of less than 90 degrees.In the preferred embodiment, substantially pointed rear portion 82 isconfigured the same as preferred front portion 60, and preferred padframe 56 is adapted and configured to be reversed end for end. With sucha configuration, when sandpaper supported by the front end of the padbecomes worn, the pad frame can be reversed end for end so that thesandpaper at both substantially pointed portions of the pad or pad framecan be used easily and effectively.

[0040] When pad frame 56 is coupled to dust collection or vacuum housing166, dust collected through ports 84 is carried through a dust channel214 (see FIGS. 8 and 14) to a dust exhaust channel 216 (see FIG. 8)within dust exhaust housing 218 for collecting dust generated bysandpaper coupled to lower surface 58 of frame 56A.

[0041] In the preferred system, vacuum housing 166 defines the upperportion of dust channel 214 within housing 166, the lower portion ofvacuum housing being formed by the combination of a vacuum housing cover244 (see FIGS. 12 and 13) held in place by a machine screw 246, and bythe upper surface of any pad frame coupled to the lower surface ofhousing 166.

[0042] In addition to dust collection through dust ports 84 locatedthrough some versions of pad frames and pads (see, for example, dustports 84 in FIGS. 7, 12, 13, and 18), additional dust collectioncapability is also available in the preferred system. The preferredsystem comprises a sander vacuum housing 166 and pad frame system whichprovides unique, continuous air flow for dust collection in a sandercoupled to a dust collection system such as a separate vacuum cleaner ordust collector (not shown), while providing the versatility of using apad frame system. This continuous air flow providing the additional dustcollection capability of the preferred system is effective independentlyof whether dust ports such as 84 are located through the thickness ofpad frames or pads. In addition, the continuous air flow of thepreferred system helps ensure that dust which passes into dust channel214 or dust exhaust channel 216 or a collection hose does not stagnateor unduly collect in or block such passages.

[0043] Furthermore, the preferred dust collection system helps prevent apad with dust ports such as 84 located through the thickness of the padframes or pads from essentially adhering to a workpiece surface. Such aworkpiece surface adherence could otherwise occur through thesubstantial partial vacuum that is created by an effective externalvacuum cleaner or dust collector. However, the continuousdust-collection air flow of the preferred system substantiallyeliminates such an adherence of pads to a workpiece surface.

[0044] The preferred dust collection system has particular applicationto a pad frame system for supporting sanding pads having varyingcharacteristics or geometries, but it is not limited to such a system ofpad frames, nor is it limited to in-line sanding systems. For example,the preferred dust collection system has application to corner or detailsanding systems which employ rotationally-oscillating, pivoting, ororbital sanding motions.

[0045] The preferred dust collection system comprises a vacuum housingsuch as housing 166 adapted and configured to be coupled to a motorizedsanding mechanism of a sander so that the vacuum housing moves in asanding motion. In one preferred embodiment, the vacuum housing definesat least the upper portion of a dust channel such as dust collectionchannel 214 within the housing. The dust channel in the vacuum housingis adapted and configured for connection to a dust collection system.

[0046] The preferred dust collection system further comprises a padframe (e.g., a pad frame such as frame 56 described above, or pad framessuch as 88, 130, or 140, described below; see, for example, FIGS. 12 and18) arranged and configured to be coupled under the vacuum housing inorder to move the lower surface of an attached frame so coupled in asanding motion. The pad frame comprises a relatively soft sanding pad,described below, for supporting sandpaper.

[0047] The preferred dust collection system comprises a vacuum housingwhich defines air flow dust ports 240 proximate the upper surface of theattached pad frame in a lower portion of the vacuum housing. Air flowdust ports such as 240 permit a continuous flow of air during dustcollection from a region outside the vacuum housing proximate the uppersurface of the attached pad frame, through a vacuum housing dust channelsuch as 214, and to the separate vacuum cleaner or dust collector.

[0048] With the preferred dust collection system, airborne dustproximate air flow dust ports such as 240 will be drawn continuouslyinto the separate vacuum cleaner or dust collector.

[0049] In alternate embodiments (not shown), dust ports such as 240could be formed or defined entirely by a lower portion of a vacuumhousing such as 166 (e.g., by apertures defined completely by thehousing proximate the upper portion of a pad frame or pad), or dustports such as 240 could be defined by portions of the upper surface of apad frame or pad adjacent a lower portion of a vacuum housing.

[0050] Preferred: sander body 50 comprises a substantially barrel-shapedportion 86. The barrel-shaped portion of preferred sander body 50 has adiameter substantially equal to or less than the maximum width 76 of thesander body, so that the barrel-shaped portion of the sander body isadapted and configured to be grasped by a user's hand. As is explainedfurther below, dust exhaust housing 218 may be optionally removed. Withdust exhaust housing 218 in place, a user's fingers can wrap aroundbarrel-shaped portion 86, and fit within a opening 242 located betweenbarrel-shaped portion 86 and dust exhaust housing 218.

[0051] An alternate preferred sanding pad or pad frame useful with thepresent sander or sanding system is sometimes referred to in the presentapplication as a shutter pad or pad frame. FIGS. 17 and 18 illustrate apreferred shutter pad frame 88 and pad 88A, which has at least oneextended substantially linear side edge 90 which is alignedsubstantially parallel to the linear oscillating motion and whichextends laterally a conspicuous distance 94 beyond the maximum width ofthe sander body. In FIG. 17, line 96 represents a top plan viewprojection of the maximum width of sander body 50 projected ontopreferred pad frame 88 in order to illustrate the conspicuous distance94 beyond the maximum width of the sander body that preferred pad frame88 extends. With such a configuration, when the sander is in use on aproject such the louvers on a shutter (not shown), where a lowerworkpiece upper surface (not shown) is below an upper workpiece (notshown) by a distance greater than a thickness 92 of the shutter pad andpad assembly but is inaccessible by the sander body, sandpaper supportedby the pad below the at least one extended substantially linear sideedge can be effectively used on the inaccessible lower workpiece uppersurface within the conspicuous distance 94 that the at least oneextended substantially linear side edge 90 protrudes laterally beyondthe sander body.

[0052] In the preferred embodiment shown in FIG. 17, distance 94 isapproximately 1.6 inches. Other distances 94 could also be used. Inaddition, a similar shutter pad or pad frame could have two extendedsubstantially linear side edges each protruding laterally a conspicuousdistance beyond each side of the sander body.

[0053] As with preferred pad frame 56, preferred sanding pad frame 88defines dust ports 84 (see FIG. 17). When pad frame 88 is coupled todust collection housing 166, dust collected through ports 84 is carriedthrough a dust channel 214 (see FIGS. 8 and 14) to a dust exhaustchannel 216 (see FIG. 8) within dust exhaust housing 218 for collectingdust generated by sandpaper coupled to the lower surface of pad 88A.

[0054] Preferred substantially flat portions of corner or detail padframe 56 and preferred shutter pad frame 88 have a nominal thickness 92(see FIG. 18) of approximately 0.125 inch, although other thicknessescould be used.

[0055] Pad frames such as 56, 88, 130, and 140 typically comprise or areformed of a relatively hard, structural material. For example, such padframes can be formed of ABS polycarbonite plastic.

[0056] Pads such as 56A and 88A may be attached to frames such as 56 and88 by a cross-linked acrylic pressure sensitive adhesive (PA). The padsmay comprise either a substantially flat lower surface adapted to securesandpaper or the like to the bottom of the pads with releasable pressuresensitive adhesive (such that the pads might be referred to as PA pads),or the lower surface of the pads such as 56A and 88A may comprise a hookand loop system (such that the associated pads might be referred to ashook and loop pads).

[0057] PA pads may be formed of neoprene foam rubber having a thicknessof, for example, 0.25 inch. The upper portion of hook and loop pads maybe formed of mini-cell urethane having a thickness, for example of 0.20inch. Other systems for securing an abrasive surface or the like to thepads or pad frames could also be used.

[0058] In the preferred sanding system, profiled sanding pads such aspads 98-128 (see FIGS. 28-44) are adapted and configured to be coupledto the in-line oscillating mechanism. Each profiled sanding pad 98-128has, in a plane substantially perpendicular to the linear oscillatingmotion, a particular cross sectional profile corresponding to a profileto be formed onto or to be sanded on a workpiece. The cross sectionalconfiguration typically extends substantially consistently along theentire length of the profiled pad. Pads 98-128 respectively definesanding surfaces 98S-128S, with each such sanding surface having aprofile corresponding to the particular cross sectional profile desired.With such a system, sandpaper secured to the sanding surface of aprofiled sanding pad will power sand the selected profile to be formedonto or to be sanded on a workpiece (cross sectional profiles inaddition to those shown in FIGS. 28-44 may be employed, and that anysuch configurations may include or be used to sand or form profilescommonly formed onto or to be sanded on a workpiece, as well as thosenot commonly formed or sanded).

[0059] Profiled pads such as pads 98-128 may be formed of nitrilebutadiene rubber (NBR) having a nominal hardness of 80 on the shorescale. Other materials and hardness may also be employed. Varyinghardness can affect the amount of material removed by the pads.Sandpaper can be secured to such pads using pressure sensitive or otheradhesives, or other approaches might be used to secure abrasive to thesanding surfaces of pads 98-128.

[0060] Preferred profiled pads such as pads 98-128 for use with thepresent system may have a length of approximately 2.75 inches, althoughpads in other lengths may be configured as needs dictate.

[0061] Preferred in-line oscillating mechanism 54 is adapted andconfigured to selectively receive and move in a linear oscillatingmotion at least one of a plurality of profiled sanding pads selectablefrom a system of profiled sanding pads, and a preferred sander comprisesa system of profiled sanding pads such as pads 98-128. Each profiledsanding pad within the system is adapted and configured to beselectively coupled to in-line oscillating mechanism 54, and eachprofiled sanding pad has, in a plane substantially perpendicular to thelinear oscillating motion, a distinct particular cross sectional profilecorresponding to a profile to be formed onto or to be sanded on aworkpiece. The cross sectional configuration of any profiled pad in thesystem typically extends substantially consistently along the length ofthe pad, and each profiled pad in the system defines a sanding surface98S-128S having a profile corresponding to the distinct particular crosssectional profile of the pad. With such a system, sandpaper secured tothe sanding surface of any profiled pad in the system will, when thecorresponding pad is coupled to in-line oscillating mechanism 54, powersand the profile having the distinct particular cross section of theselected pad.

[0062] In the preferred sanding system, in-line oscillating mechanism 54is adapted and configured to move in a linear oscillating motion aplurality of profiled sanding pads selected from the system of profiledsanding pads. In this embodiment, the selected pads are typicallycoupled at spaced-apart locations onto the in-line oscillatingmechanism. With such an arrangement, sandpaper secured to the sandingsurfaces of the profiled pads will, when the selected plurality pads arecoupled to the in-line oscillating mechanism, selectively andalternately power sand onto the workpiece the profiles having thedistinct particular cross sections of the selected plurality of padssecured to the in-line oscillating mechanism.

[0063] The preferred sanding system comprises a variety of pad framesadapted and configured to be coupled to in-line oscillating mechanism54. In the preferred embodiment, this is accomplished through a vacuumhousing 166 which is coupled to the in-line oscillating mechanism 54,and vacuum housing 166, which moves in linear oscillating motion, isadapted and configured to be selectively coupled to a plurality ofsanding pads frames such as corner or detail pad frame 56, shutter padframe 88, or profiled pad frames 130 or 140, which in turn are adaptedand configured to position one or more profiled pads 98-128 for in-linepower sanding. With such a system, the present sander or sanding systemcan be alternately and selectively adapted and configured as either apower corner or detail sander, a power shutter sander, or a powerprofile sander.

[0064] Pads or pad frames such as 56, 130, and 140 are adapted andconfigured in the preferred embodiment to be selectively andconveniently connected to in-line oscillating mechanism 54 by snappingthe pad frames into the lower portion of vacuum housing 166. Each ofpreferred pad frames 56, 130, and 140 comprise two in-line,upwardly-protruding vertical members 222 having at their upper endsforward and back facing hooked portions 224 which are secured withinvacuum housing 166 by fixed or moveable flanges. A rear-facing, hookedportion 224 on a rear vertical member 222 on each pad frame engages witha forward-facing, fixed flange 226 (see FIG. 9) formed within vacuumhousing 166. A forward facing hooked portion 224 on a front verticalmember on each pad frame engages a moveable, forward-facing flange 228(see FIGS. 9 and 12) located on the underside of a releasable sliding orlocking button 230.

[0065] Releasable sliding button 230 is biased by a spring 232, and isreleasably secured into a front upper portion of vacuum housing 166 bybiased, sliding side portions 234 on button 230, the biased, slidingside portions 234 being received by grooves 236 defined by the openingformed into the front upper portion of the vacuum housing for receivingbutton 230.

[0066] Hooked members 238 formed on the ends of biased, sliding sideportions 234 of button 230 maintain the button in a normal, installedposition within vacuum housing 166. Button 230 can be removed forreplacement or the like by pulling the button outward whilesimultaneously pushing the biased, sliding side portions 234 toward oneanother in order to release hooked members 238 from grooves 236.

[0067] In normal operation of button 230 for releasing or more easilyinstalling a sanding pad frame, button 230 is pushed into the vacuumhousing. This inward movement of button 230 releases front-facing,movable flange 228 within button 230 away from rear-facing hook 224 onthe front vertical member 222 of any preferred sanding pad frame, thusallowing removal of the pad frame from vacuum housing 166. Such removalis facilitated by moving the pad frame simultaneously slightly forwardand downward, in order to also release the rear facing hook 224 on therear vertical member 222 of the pad frame frontward and downward awayfrom forward facing permanent flange 226, thus releasing the pad frame.

[0068] A new pad frame can be inserted onto vacuum housing 166 by simplyinserting the pad frame vertical members 222 up into the vacuum housingso that the rear facing hook 224 on the rear vertical member 222 engagesforward facing, permanently-placed flange 226, while engaging therear-facing hook 224 on the front vertical member 222 up and into themovable front-facing flange 228 on releasable spring-biased button 230.

[0069] In addition to being secured by vertical members 222 as describedabove, preferred pad frames 56, 88, 130, and 140 each comprise fourstability projection members 248. In the preferred embodiment, two ofstability projection members 248 are located toward the front portion ofeach pad frame and bear snugly up against the inside of the frontinterior walls of vacuum housing 166, and two of the stabilityprojection members 248 are located toward the rear portion of each padframe and bear snugly up against vacuum housing cover 244 bearingsurfaces 250, which are geometrically symmetrical to the front interiorwalls of vacuum housing 166. This snug interface between projectionmembers 248 and the interior side of the front walls of vacuum housing166 and bearing surfaces 250 substantially eliminate in-line movement ofthe pad frames or pads with respect to the vacuum housing.

[0070] One profiled pad holding system 130 (see, for example, FIGS. 10,12, and 22-24) useful with the present sanding system is adapted andconfigured to hold a single profiled sanding pad such as any one of pads98-128. In the preferred system, pads 98-128 have an upper portiondefining a particular holding cross sectional configuration 98H-128Hpreferably extending substantially consistently along the length of thepad. Preferred holding system 130 defines a single, substantiallydownward-facing channel 132 having first and second sides 134 and 136respectively configured to secure any one of holding cross sectionalconfigurations 98H-128H of the profiled pads.

[0071] Preferred profiled sanding pad holding system 130 further definessubstantially-vertically-oriented ridges 138 on the inner surfaces ofsidewalls 134 and 136 of substantially downward-facing channel 132 toassist in securing the holding cross sectional configurations of theprofiled pads. It has been found that ridges 138 may be configured witha 0.015 inch flat on the tip of the ridges, and each ridge has concaveradial sides. Other configurations could also be used. In addition,different arrangements entirely could be used, e.g., a T-slotconfiguration.

[0072] Profiled sanding pad holding system 130 preferably is furtherarranged and configured so that, when the profiled sanding pad iscoupled to the in-line oscillating mechanism, at least a portion of theparticular cross sectional profile 131 (see, for example, FIG. 8)protrudes ahead of front end 68 of the sander body throughout the linearoscillating motion of the pad. With such an arrangement, when sandpaperis secured to at least the portion 131 of the particular cross sectionalprofile which protrudes ahead of the front end of the sander bodythroughout the linear oscillating motion of the pad, the protrudingportion can be used to power sand the profile to be formed onto or to besanded on a workpiece on a surface which is otherwise blocked fromaccess by the sander body.

[0073] An alternate profiled sanding pad holding system 140 (see FIGS.12 and 19-21) defines two substantially downward-facing channels 142 and144. In the preferred embodiment, each channel 142 and 144 comprisesfirst and second sidewalls 148 and 150 aligned lengthwise in-line withthe linear oscillating motion. Sidewalls 148 and 150 are configured tosecure the holding cross sectional configurations of the profiled pads.As with channel 132, channels 142 and 144 preferably comprisesubstantially-vertically-oriented ridges 138 on the inner surfaces ofsidewalls 148 and 150 to assist in securing the holding cross sectionalconfigurations of the profiled pads in the channels.

[0074] In the preferred configuration of alternate profiled sanding padholding system 140 (see FIGS. 10A, 12, and 19-21), the two substantiallydownward-facing channels 142 and 144 are each angled at least slightlyoutward from one another and are located so that any of the preferredprofiled sanding pads 98-128 secured within either of the two channelshas at least a portion of the pad sanding surface projecting laterallypast the sander body maximum width (see FIG. 10A). Using the profiledsanding pad orientation achieved through preferred alternate pad holdingsystem 140, with sandpaper secured to the sanding surfaces of selectedpads mounted in channels 142 and 144, at least a portion of selectedparticular cross sectional profiles can with power sanding be formedonto or sanded on a workpiece surface that might otherwise be blocked bythe sander body.

[0075] It is further preferred that the configuration of alternateprofiled sanding pad holding system 140 comprise the two substantiallydownward-facing channels each being located such that any profiledsanding pad secured within either of the two channels may be positionedso that at least a portion of the pad sanding surface protrudes ahead ofthe front end of the sander body throughout the linear oscillatingmotion of the pad. This is accomplished through placement of the forwardend of channels 142 and 144 as far forward on holding system 140 as theforward end of channel 132 is placed on holding system 130 (see FIG.12). Accordingly, with holding system 140 mounted to the sander, theforward portion of channels 142 and 144 are located ahead of the frontend 68 of the sander body, similarly to the position of the forwardportion of channel 132 shown in FIG. 8. Therefore, with sandpapersecured to the sanding surfaces of selected pads mounted in the forwardportions of channels 142 and 144, at least a portion of selectedparticular cross sectional profiles can with power sanding be formedonto or sanded on a workpiece surface that might otherwise beinaccessible by the sander body.

[0076] While motor 52 is illustrated in FIG. 8 as an electric motorcontrolled by power switch 51 (see FIG. 1) and powered by line voltagecoupled through power cord boot 53, the motor could be an electric motorpowered by a rechargeable battery system, or it could be an air-poweredmotor. In the preferred embodiment, motor 52 typically has a nominalspeed of approximately 18,000 revolutions per minute, and a three-to-onegear ratio may be used to turn the horizontal motor output verticallyand to reduce the speed of rotation so that a nominal in-line strokespeed of approximately 6,000 strokes per minute (spm) is achieved. Astroke length of approximately 0.080 inch has been found acceptable incombination with the nominal stroke speed of approximately 6000 spm.

[0077] In developing the present system, the assignee of the presentsystem experimented with a stroke length of approximately 0.060 inchwith a stroke speed of approximately 18,000 spm, as well as with astroke length of approximately 0.125 inch at stroke speed ofapproximately 9,000 spm. The small 0.060 inch stroke length at therelatively high speed of 18,000 spm resulted in relatively littlematerial removal with some sanding pad configurations, and the largerstroke length of 0.125 at the speed of 9,000 spm typically causedaggressive removal of material but was found more difficult to controlin some circumstances and to be relatively noisy. The selected strokelength of 0.080 inch at 6,000 spm was found to provide a combination ofcontrol, stock removal, and quietness. Other stoke lengths and speedsmay also be acceptable, including variable stroke speed attained throughthe use of motor speed control.

[0078] Motor 52 powers the present in-line oscillating mechanism 54through a set of face gears including a pinion face gear 152 (see FIG.8) mounted on the end of motor shaft 154, which is secured intorotational position by bearings 156 having outer races secured withinsander body 50. Pinion face gear 152 meshes with a horizontal face gear158, which is shown schematically in, for example FIGS. 8, 11, 13, and15.

[0079] Face gear 158 is coupled to vertical drive shaft 160 heldrotationally in place at the upper end of the shaft by an upper bearing162 having an outer race coupled to a bearing housing 164 secured withinsander body 50. Vertical drive shaft 160 is held rotationally in placeat a lower portion of the shaft by a lower bearing 163, which has anouter race secured within a cavity 179 (see FIG. 13) of a bearing plate174 by an o-ring 184 (see FIGS. 8 and 10). Bearing plate 174 is firmlyattached to sander body 50 by two machine screws 180 (see FIG. 10), eachof which thread into a tapped hole 182 (see FIGS. 11 and 15), one oneach side of bearing plate 174 (note: FIG. 13 is schematic and does notshow a tapped hole 182 on the visible side of bearing plate 174). Thelower portion of vertical drive shaft 160 is coupled to a scotch yokemechanism that causes vacuum housing 166 to move in a linear oscillatingmotion.

[0080] Vacuum housing 166 comprises four substantially vertical risers168, each of which include at an upper portion a bronze bushing 170. Thefour bronze bushings 170 secured in the upper portion of vertical risers168 provide sliding support to dowel pins 172, which pass through andare firmly attached to bearing plate 174. Accordingly, vacuum housing166, supported by the four vertical risers 168 with bronze bushingssliding on dowel pins 172, is caused to move in a liner oscillatingmotion by a scotch yoke mechanism, which will now be described.

[0081] A lower portion of drive shaft 160 comprises an eccentric shaftportion 186, which guides the inner race of vacuum-housing drive bearing188. The outer race of vacuum-housing drive bearing 188 rides within anelongated opening 190 defined by a vacuum housing drive plate 192, 193(note: a first embodiment of the vacuum housing drive plate, labeled192, is shown in FIGS. 12, 13, and 14; a second embodiment of the vacuumhousing drive plate, labeled 193, is shown in FIG. 16). The vacuumhousing drive plate is secured to the vacuum housing by two machinescrews 194 (see FIG. 8), the lower portion of machine screws 194 beingsecured by hex nuts 196 set within recesses 198 on the underside ofvacuum housing 166 (see FIG. 12).

[0082] Elongated opening 190 defined by the vacuum housing drive platehas a width along the linear oscillating motion substantially equal tothe outer diameter of vacuum-housing drive bearing 188, which rideswithin elongated opening 190.

[0083] The length of elongated opening 190 across the linear oscillatingmotion is substantially greater than the outer diameter of vacuumhousing drive bearing 188. This shape of elongated opening 190 causesthe outer race of vacuum-housing drive bearing 188, which iseccentrically mounted on drive shaft portion 186, to move the vacuumhousing in the in-line oscillating motion.

[0084] Sander body vibration which might otherwise be caused by thein-line oscillating motion of the vacuum housing and attached pad frameand pad is substantially offset by a counterweight 200, 201 (note: afirst embodiment of the counterweight, labeled 200, is shown in FIGS.11, 13, and 15; a second embodiment of the counterweight, labeled 201,is shown in FIG. 16). The counterweight is caused to move with anin-line oscillating motion 180 degrees out of phase with the in-linemovement of the vacuum housing, as will now be described in more detail.

[0085] A lower portion of drive shaft 160 just above eccentric driveshaft portion 186, comprises a second eccentric portion 202 which iseccentrically out of phase by 180 degrees with eccentric portion 186.Eccentric portion 202 guides the inner race of a counterweight drivebearing 204. The outer race of counterweight drive bearing 204 rideswithin an elongated opening 206 (see FIGS. 13 and 16) defined by thecounterweight.

[0086] Elongated opening 206 defined by the counterweight has a widthalong the linear oscillating motion substantially equal to the outerdiameter of counterweight drive bearing 204, which rides withinelongated opening 206. The length of elongated opening 206 across thelinear oscillating motion is substantially greater than the outerdiameter of counterweight drive bearing 204. This shape of elongatedopening 206 causes the outer race of counterweight drive bearing 204,which is eccentrically mounted on drive shaft portion 202, to move thecounterweight in an in-line oscillating motion, 180 degrees out of phasewith the inline oscillating motion of vacuum housing 166.

[0087] The counterweight is guided in an in-line oscillating motion bytwo bushings 208 (see FIG. 16), which ride within slots 210 elongated inline with the in-line oscillating motion (note: slots 210 are offset incounterweight embodiment 200, as shown in FIGS. 11, 13, and 15, and arealigned in counterweight embodiment 201, as shown in FIG. 16). Bushings208 are held in place for guiding the counterweight by machine screws212 (FIG. 8) secured to the vacuum housing drive plate.

[0088] With the weight of the counterweight and the combined weight ofvacuum housing 166 and any pad frame and corresponding attached pad andabrasive being substantially equal, vibration of sander body 50 in auser's hand is substantially reduced or eliminated.

[0089] Vacuum housing 166 defines dust channel 214 (see FIGS. 8 and 14)for guiding dust collected through dust ports 84 and air flow dust ports240 to a dust exhaust channel 216 within dust exhaust housing 218. Adust collection hose (not shown) may be connected on one end fitting 219on the exit end of dust exhaust housing 218 and on the other end to asuitable separate vacuum cleaner or dust collector for collecting dustcreated by the sander.

[0090] A rear portion 256 (see FIGS. 8, 9, and 14) of the vacuum housingassembly (the assembly of vacuum housing 166 and vacuum housing cover244) fits into the upstream or forward end of dust exhaust housing 218.A sliding interface between the exterior walls of portion 256 and theinterior walls of dust exhaust housing 218 permits portion 256 of thevacuum housing assembly to move in an in-line oscillating motion withinforward end of dust exhaust housing 218.

[0091] Dust exhaust housing 218 may be optionally removed by looseningthumb screw 220, which then permits housing 218 to be removed, such asto provide a lighter or more maneuverable sander (e.g., when no dustcollection is desired, or in tight operating conditions). In thepreferred embodiment, when thumb screw 220 is loosened, dust exhausthousing 218 is easily removed by pulling housing 218 down and away fromthe front of the sander (when installed, the forward portion of housing218 is held in place by a pin 258 which fits into an corresponding holein the sander body).

[0092] The present invention is to be limited only in accordance withthe scope of the appended claims, since persons skilled in the art maydevise other embodiments still within the limits of the claims. Forexample, many of the preferred features of the present sander or sandersystems described in the present application are not limited to anin-line sander.

What is claimed is:
 1. An in-line sander comprising: an elongated sanderhousing configured to be grasped by a user of the in-line sander; asanding pad holding portion defining an outwardly facing channel thatopens outward from the sander housing and that extends in a directiongenerally along a length of the sander housing, the channel beingarranged and configured for receiving and holding a profiled sandingpad; a motor housed within the housing; and an in-line oscillatingmechanism operatively coupled between the motor and the sanding padholding portion, the in-line oscillating mechanism being arranged andconfigured to move the sanding pad holding portion in a linearoscillating motion, the linear oscillating motion being in the directiongenerally along the length of the housing.
 2. The in-line sander ofclaim 1, wherein the profiled sanding pad is secured within the channelof the sanding pad holding portion, and the profiled sanding pad has, ina plane substantially perpendicular to the linear oscillating motion, aparticular cross sectional profile which defines, substantiallyconsistently along the length of the pad, a profile sanding areaincluding portions not aligned on a single common plane.
 3. The in-linesander of claim 2, wherein the profiled sanding pad is oriented suchthat a portion of the pad protrudes ahead of a front end of the sanderhousing throughout the linear oscillating motion.
 4. The in-line sanderof claim 2, wherein the sanding area of the profiled sanding padincludes a curved sanding surface.
 5. The in-line sander of claim 2,wherein the sanding area of the profiled sanding pad includes aplurality of planar sanding surfaces interconnected at discrete edges.6. The in-line sander of claim 1, further comprising a plurality ofprofiled sanding pads adapted to be interchangeably secured within thechannel of the sanding pad holding portion, each of the profiled sandingpads having a different cross sectional profile.
 7. The in-line sanderof claim 1, wherein the channel has a generally U-shaped cross section.8. The in-line sander of claim 1, wherein the sanding pad holdingportion includes a plurality of projections that extend into thechannel, the projections being arranged and configured for assisting inretaining the profiled sanding pad within the channel.
 9. The in-linesander of claim 8, wherein the projections comprise ridges.
 10. Thein-line sander of claim 9, wherein the ridges have an opposingrelationship.
 11. The in-line sander of claim 10, wherein the ridges arearranged in a substantially vertical orientation.
 12. The in-line sanderof claim 1, wherein the profiled-sanding pad is frictionally retainedwithin the channel of the pad holding portion.
 13. The in-line sander ofclaim 12, wherein the profiled sanding pad has elastic characteristics,and portions of the profiled sanding pad are deformed when the pad isinserted in the channel such that the pad is frictionally retained inthe channel.
 14. The in-line sander of claim 13, wherein the pad holdingportion includes projections that extend into the outwardly facingchannel, the projections being arranged and configured to deform theportions of the profiled sanding pad when the profiled sanding pad isinserted within the outwardly facing channel.
 15. The in-line sander ofclaim 2, wherein the sanding pad holding portion comprises a pad frameon which the outwardly facing channel is defined, the pad frameincluding means for detachably coupling the pad frame to the in-lineoscillating mechanism.
 16. The in-line sander of claim 15, wherein thepad frame includes substantially pointed front and back portions, andsubstantially parallel portions located between the front and backportions.
 17. The in-line sander of claim 1, wherein the channel of theprofiled sanding pad holding portion is defined by opposing first andsecond holding members.
 18. The in-line sander of claim 17, wherein theprofiled sanding pad is more elastic than the first and second holdingmembers, and the profiled sanding pad is arranged and configured todeform when inserted between the first and second members.
 19. Thein-line sander of claim 18, wherein the first and second holding membersinclude a plurality of projections that extend into the channel, theprojections being arranged for assisting in retaining the profiledsanding pad within the channel.
 20. The in-line sander of claim 19,wherein the projections comprise ridges.
 21. The in-line sander of claim20, wherein the ridges have an opposing relationship.
 22. The in-linesander of claim 21, wherein the ridges are arranged in a substantiallyvertical orientation.
 23. The in-line sander of claim 2, furthercomprising an abrasive material attached to the profiled sanding pad.24. The in-line sander of claim 23, wherein the abrasive materialcomprises sandpaper.
 25. The in-line sander of claim 12, wherein theprofiled sanding pad has a base end configured to be inserted in thechannel of the pad holding portion, the base end of the profiled sandingpad being tapered.
 26. The in-line sander of claim 1, wherein the padholding portion defines two spaced-apart outwardly facing channelsextending lengthwise along the sander housing, the channels beingarranged and configured for receiving and holding profiled sanding pads.27. The in-line sander of claim 26, wherein the channels are angledoutward from one another.
 28. An in-line sander comprising: a sanderhousing including an elongated main portion and a head portion, the mainportion being configured to be grasped by a user of the sander, and thehead portion projecting laterally outward from one end of the mainportion, wherein the head portion forms a sanding end that is laterallyoffset from the main portion such that finger clearance is providedbetween the main portion and a surface to be sanded; a pad holderlocated at the sanding end of the sander housing; a profiled sanding padpositionable within the pad holder, the sanding pad having a transversecross sectional profile which defines, substantially consistently alongthe length of the pad, a sanding area corresponding to a profile to besanded on a workpiece, the sanding area including portions not alignedon a single common plane; a motor housed within the housing; and anin-line oscillating mechanism operatively coupled between the motor andthe pad holder, the in-line oscillating mechanism being arranged andconfigured to move the pad holder in a linear oscillating motion in adirection generally along the length of the sander housing, whereby whenthe motor is actuated and the profiled sanding pad is positioned in thepad holder, abrasive material secured to the sanding area of theprofiled sanding pad is adapted to power sand the workpiece.
 29. Thein-line sander of claim 28, wherein the sanding area of the profiledsanding pad includes a curved sanding surface.
 30. The in-line sander ofclaim 28, wherein the sanding area of the profiled sanding pad includesa plurality of planar sanding surfaces interconnected at discrete edges.31. The in-line sander of claim 28, further comprising a pad holdingportion located at the sanding end of the sander housing, the padholding-portion defining a downwardly facing channel in which theprofiled sanding pad is retained.
 32. The in-line sander of claim 31,wherein the pad holding portion includes projections that extend intothe channel and that engage and deform the profiled sanding pad.
 33. Thein-line sander of claim 32, wherein the projections comprise opposingridges.
 34. The in-line sander of claim 31, wherein the channel has agenerally U-shaped cross section.
 35. The in-line sander of claim 28,wherein the elongated main portion of the sander housing is generallybarrel-shaped.
 36. The in-line sander of claim 35, wherein the elongatedmain portion of the sander housing has a diameter equal to or less thana maximum width of the sander housing.
 37. The in-line sander of claim28, wherein the abrasive material is sandpaper.
 38. An in-line sandercomprising: an elongated sander housing configured to be rasped by auser of the in-line sander; a sanding pad holding portion defining anoutwardly facing channel that opens outward from the sander housing andthat extends lengthwise along the sander housing; means for connectingthe sanding pad holding portion to the sander housing; a profiledsanding pad; means for frictionally retaining the profiled sanding padwithin the outwardly facing channel; a motor housed within the sanderhousing; and means for operatively coupling the motor to the pad holdingportion such that the motor is configured to move the sanding padholding portion in a linear oscillating motion, the linear oscillatingmotion being in a direction generally along the length of the housing.39. An in-line sander comprising: a sander housing including abarrel-shaped portion and a head portion, the barrel-shaped portionbeing configured to be grasped by a user of the sander, thebarrel-shaped portion being aligned along a longitudinal axis andincluding a bottom side adapted to face a surface to be sanded by thein-line sander, and the head portion projecting transversely outwardfrom one end of the barrel-shaped portion such that the head portionforms a sanding end that is downwardly offset from the bottom side ofthe barrel-shaped portion, wherein the offset provides finger clearancebetween the bottom side of the barrel-shaped portion and the surface tobe sanded; a pad holder located at the sanding end of the housing; aprofiled sanding pad positionable within the pad holder, the sanding padincluding a length aligned substantially parallel to the longitudinalaxis of the barrel-shaped portion, and the sanding pad having atransverse cross sectional profile which is substantially uniform alongthe length of the pad, and which defines a sanding area includingportions not aligned on a single common plane; a motor housed within thehousing; and an in-line oscillating mechanism operatively coupledbetween the motor and the pad holder, the in-line oscillating mechanismbeing arranged and configured to move the pad holder in a linearoscillating motion in a direction generally parallel to the longitudinalaxis of the barrel-shaped portion, whereby when the motor is actuatedand the profiled sanding pad is positioned within the pad holder,abrasive material secured to the sanding area of the profiled sandingpad is adapted to power sand a workpiece.
 40. The in-line sander ofclaim 39, wherein the one end of the barrel-shaped portion is sized andshaped to correspond with the user's palm, and a gripping depression isdefined between the barrel-shaped portion and the head portion of thesander housing, the gripping depression being arranged and configuredfor receiving the user's fingers when the user's palm is placed on theone end of the barrel-shaped portion.